Professional Documents
Culture Documents
MHM-97453, rev. 0
March 2011
Copyright
2011 by Emerson Process Management. All rights reserved.
No part of this publication may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any
language in any form by any means without the written
permission of Emerson Process Management.
Disclaimer
This manual is provided for informational purposes. Emerson
Process Management makes no warranty of any kind with regard
to this material, including, but not limited to, the implied
warranties of merchantability and fitness for a particular
purpose. Emerson Process Management shall not be liable for
errors, omissions, or inconsistencies that may be contained
herein or for incidental or consequential damages in connection
with the furnishing, performance, or use of this material.
Information in this document is subject to change without
notice and does not represent a commitment on the part of
Emerson Process Management. The information in this manual
is not all-inclusive and cannot cover all unique situations.
Patents
The product(s) described in this manual are covered under
existing and pending patents.
License Agreement
IMPORTANT: CAREFULLY READ ALL THE TERMS AND CONDITIONS OF
THIS AGREEMENT BEFORE OPENING THE PACKAGE OR PROCEEDING
WITH INSTALLATION. OPENING THE PACKAGE OR COMPLETING THE
INSTALLATION INDICATES YOUR ACCEPTANCE OF THE TERMS AND
CONDITIONS CONTAINED IN THIS AGREEMENT.
IF YOU DO NOT AGREE TO THE TERMS AND CONDITIONS CONTAINED
IN THIS AGREEMENT, CANCEL ANY INSTALLATION AND PROMPTLY
RETURN THIS PRODUCT AND THE ASSOCIATED DOCUMENTATION TO
CSI, AND YOUR MONEY WILL BE REFUNDED. NO REFUNDS WILL BE
GIVEN FOR PRODUCTS WITH DAMAGED OR MISSING COMPONENTS.
Definition of Software
As used herein, software refers to any computer program contained
on any medium. Software includes downloadable firmware for use in
devices such as analyzers or MotorStatus units and it includes
computer programs executable on computers or computer networks.
Software License
You have the non-exclusive right to use this software on only one
device at a time. You may back-up the software for archival purposes.
For network systems, you have the non-exclusive right to install this
software on only one server. Read/write access is limited to the
number of concurrent use licenses purchased. The number of guestonly accesses is up to a maximum of 250.
CSI grants you a non-exclusive right to use the Software solely for
your own internal data processing operations on the CSI-designated
supported operating platform for up to any applicable maximum
number of licensed users. You may not relicense the Software or use
the Software for third-party training, commercial time sharing,
rental, or service bureau use. Client may not use the Software in, as, or
with an Application Service Provider (ASP).
Software Updates
CSI agrees to provide you, at no charge except for media,
preparation and shipping charges, for one (1) year from the date
of purchase, all updates to the software made at the sole
discretion of CSI. Should you purchase a software support
agreement for the next succeeding year following the first year
from the date of purchase, and thereafter on an annual basis,
and if CSI is still providing support, you may purchase the same,
annually, at the then existing rate.
Updates/Upgrades
Upon receipt of new CSI software replacing older CSI software,
you have 30 days to install and test the new CSI software on the
same or a different device. At the end of the 30-day test period,
you must both remove and return the new CSI software or
remove the older CSI software.
Ownership
The licensed software and all derivatives are the sole property of
Computational Systems, Inc. You may not disassemble,
decompile, reverse engineer or otherwise translate the licensed
program. You may not distribute copies of the program or
documentation, in whole or in part, to another party. You may
not in any way distort, or otherwise modify the program or any
part of the documentation without prior written consent from
CSI.
Transfer
You may transfer the software and license to another party only with
the written consent of CSI and only if the other party agrees to accept
the terms and conditions of this Agreement. If you transfer the
program, you must transfer the documentation and any backup
copies or transfer only the documentation and destroy any backup
copies.
Copyright
The software and documentation are copyrighted. All rights are
reserved.
Termination
If you commit a material breach of this Agreement, CSI may terminate
the Agreement by written notice.
Virus Disclaimer
CSI uses the latest virus checking technologies to test all its software.
However, since no antivirus system is 100% reliable, we strongly
advise that you use an anti-virus system in which you have confidence
to verify the software is virus-free. CSI makes no representations or
warranties to the effect that the licensed software is virus-free.
No Warranty
THE PROGRAM IS PROVIDED AS-IS WITHOUT ANY WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY
WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE.
Export Restrictions
You agree to comply fully with all laws, regulations, decrees and
orders of the Unites States of America that restrict or prohibit
the exportation (or re-exportation) of technical data and/or the
direct product of it to other countries, including, without
limitation, the U.S. Export Administration Regulations.
Hardware Repair
Emerson Process Management repairs and updates its hardware
products free for one year from the date of purchase. This service
warranty includes hardware improvement, modification, correction,
recalibration, update, and maintenance for normal wear. This service
warranty excludes repair of damage from misuse, abuse, neglect,
carelessness, or modification performed by anyone other than
Emerson Process Management.
After the one year service warranty expires, each return of a Emerson
Process Management hardware product is subject to a minimum
service fee. If the cost of repair exceeds this minimum fee, we will call
you with an estimate before performing any work. Contact Emerson
Process Managements Product Support Department for information
concerning the current rates.
Obsolete Hardware
Although Emerson Process Management will honor all contractual
agreements and will make every effort to ensure that its software
packages are backward compatible, to take advantage of advances
in newer hardware platforms and to keep our programs reasonably
small, Emerson Process Management reserves the right to
discontinue support for old or out-of-date hardware items.
you were doing when the problem occurred. For example, what
mode were you in? What steps did you go through? Try to
determine before you call whether the problem is repeatable.
3. Please be at your computer when you call. We can serve you
better when we can work through the problem together.
Reference Manual
MHM-97453.0
Contents
Special Text ..................................................................................... 3
Chapter 1
Chapter 2
Chapter 3
Reference Manual
MHM-97453.0
Chapter 4
Appendix A
Reference Manual
MHM-97453.0
March 2011
Special Text
The following conventions are used throughout this manual to call
special attention to the associated text:
Note
A note paragraph contains special comments or instructions.
CAUTION!
A caution paragraph alerts you to actions that may have a major impact
on the equipment, stored data, etc.
WARNING!
A warning paragraph alerts you actions that may have extremely
serious consequences for equipment and/or personnel.
Reference Manual
MHM-97453.0
Reference Manual
MHM-97453.0
March 2011
Reference Manual
MHM-97453.0
Reference Manual
MHM-97453.0
March 2011
Accessories
Provided accessories
In addition to the CSI 2600 and its case, the following items are
provided:
CAUTION!
Avoid hot, wet surfaces and do not block the vents or fans.
Note
You cannot operate the CSI 2600 while it is still in the case.
Reference Manual
March 2011
MHM-97453.0
Recommended accessories
Minimum laptop specifications:
2.0 GB memory
Windows XP Professional
8X DVD +/- RW
Note
The laptop is configured as an AMS Machinery Manager server.
Dell wireless LAN.
2.0 GB memory
Windows 7
Reference Manual
MHM-97453.0
March 2011
8X DVD +/- RW
Optional accessories
Sensors
Mounting pads
BNC cables
Extension cords
Optional software
PeakVue
OPC
Modbus
Optional services
Remote analysis
Reference Manual
March 2011
MHM-97453.0
Environmental
80 W consumption
Note
A 500 W UPS is recommended.
Two 10 A fuses for the power input are accessible through a small
access panel between the receptacle and the power switch. The
access panel can be opened with a flathead screwdriver.
10
Reference Manual
MHM-97453.0
March 2011
WARNING!
Make sure that the sensor power is disabled when connecting to a protection
system with unbuffered BNC outputs.
11
Reference Manual
MHM-97453.0
CAUTION!
Be sure to close the panel before powering the CSI 2600. It is not recommended to power the CSI 2600 while the rear panel is opened.
12
Reference Manual
MHM-97453.0
March 2011
CAUTION!
Whenever making connections to unbuffered sensor signals, ensure that
physical contact with these signals will not perturb other monitoring or
protection systems.
If connecting the laptop to the CSI 2600 for the first time, you will
need to use the RS-232 serial connection cable for HyperTerminal to
properly program and initialize the CSI 2600.
Monitoring communications
Monitoring communications between the CSI 2600 and the laptop
is done by way of the HUB port on the front of the CSI 2600 when
connected with the included standard ethernet cable. Alternatively,
you may use the NIC port when connecting the CSI 2600 to a local
area network.
Reference Manual
MHM-97453.0
14
Reference Manual
MHM-97453.0
March 2011
hard drive (if one is connected). Disconnect the laptop. Unplug the
CSI 2600. The CSI 2600 can now be lowered back into its case.
CAUTION!
Whenever making connections to unbuffered sensor signals, ensure that
physical contact with these signals will not perturb other monitoring or
protection systems.
15
16
Reference Manual
MHM-97453.0
Reference Manual
MHM-97453.0
March 2011
Laptop
Online Database
Ethernet cable
17
Reference Manual
MHM-97453.0
18
Reference Manual
MHM-97453.0
March 2011
2.
3.
19
Reference Manual
MHM-97453.0
CSI 2600
This is the hardware portion of the monitoring system. It is a
portable unit which is connected to the server via Ethernet.
O_server
This service is the central process which handles all non-transient
activity on the online system. It is responsible for processing most
requests from the client, sending configuration information to and
receiving data from the CSI 2600. On the laptop, this is a service
running under Computer Management > Services and Applications
> Services List.
NetAdmin
This service is responsible for handling the user's access to the
various programs within the AMS Machinery Manager software. On
the laptop, this is a service running under Computer Management >
Services and Applications> Services List.
MtDbMgr
This is the database server service which handles most of the
reading and writing operations performed on databases stored on
the server. It also indexes and verifies the integrity of databases. On
the laptop, this is a service running under Computer Management>
Services and Applications > Services list.
20
Reference Manual
MHM-97453.0
March 2011
MHMRemote
This service handles transient data generated by the CSI 2600 as well
as the database access required by the Diagnostic Analysis program.
On the laptop, this is a service running under Computer
Management > Services and Applications > Services list.
Online Configuration
Also referred to as O_config, this program allows the user to create
new and modify existing databases for use with the online system.
System commissioning is also handled through O_config. On the
laptop, this is an application inside the AMS Machinery Manager
Tools tab.
Online Watch
Also known as O_watch, this program provides the user with a
graphic interface that allows the viewing of data sent to the server
by the CSI 2600, management of transient acquisition and autoextraction, adjustment of alarm levels and on-demand data
acquisition. On the laptop, this is an application inside the AMS
Machinery Manager Tools tab.
Vibration Analysis
This application allows the user to request and save transient data,
view live streaming data and provides a variety of analysis functions
necessary for analyzing the data generated by the CSI 2600. On the
laptop, this is an application inside the AMS Machinery Manager on
the Vibration Analysis tab.
IIS FTP
Microsoft's IIS includes an FTP server which needs to be installed to
allow the CSI 2600 to load firmware from the server. On the laptop,
21
Reference Manual
March 2011
MHM-97453.0
Firmware
The firmware is a set of two files, which are loaded from the laptop
during the boot up of the CSI 2600. This allows most system
updates to be installed on the laptop like any other program update
without the requirement of any special interaction with the CSI
2600 beyond rebooting it to allow it to load the new version. The
firmware files are stored in the directory C:\Inetpub\ftproot\bin.
22
Reference Manual
MHM-97453.0
March 2011
Collection criteria
AP Set - The analysis parameter set defines a particular way to
collect spectral data. The AP Set specifies the number of lines of
resolution; any averaging modes and windowing; whether to be
order-based, what FMax to use, and what parameters are to be
collected.
AL Set - A collection of Alarm Limits. Each AL Set is associated with a
specific AP Set. There may be multiple AL Sets defined for any given
AP Set to accommodate changing monitoring conditions. The alarm
limit definition determines when alarms occur, data is stored and
output relays are set.
Collection Predicate - A predicate is an expression that compares
the conditions of vibration levels and/or input relay states to
determine when data is collected and transient auto-archives are
extracted.
23
Reference Manual
March 2011
MHM-97453.0
Logical hierarchy
Area - A user-defined grouping of equipment. An Area often
corresponds to a building or section of a process line within a plant.
Equipment - A group of coupled devices that logically should be
monitored together. Most often a machine train made up of a driver
component (such as a motor) and one or more driven components
(such as a pump or fan).
Component - A specific, single asset to be monitored, possibly with
multiple sensors. Usually a driver or driven piece of machinery.
Motors, engines, turbines, pumps, fans, etc. are examples of
components.
Measurement Point - Corresponds to a single physical sensor.
Groups together all the data from all the collections that have been
defined for a particular sensor. Any Gross Scan data collected on the
sensor and reported for storage is logically associated with the
Measurement Point in the database.
Data Collection Sets (DCS) - The DCS is a grouping item that allows
multiple collections to occur on a single Measurement Point. The
DCS combines a particular predicate (when to collect) with a
particular AP Set (what and how to collect) and a specific AL Set
(limit bands and set points.)
Physical hierarchy
CSI 2600 - The physical monitoring unit.
Signal Channel - An AC vibration or DC process input.
Tachometer Channel - A speed measurement input.
Digital I/O Channel - A discrete relay, input or output.
Field wiring
In addition to predictive monitoring, the CSI 2600 is also a portable
transient monitoring system, which means in most applications it is
24
Reference Manual
MHM-97453.0
March 2011
25
Reference Manual
March 2011
MHM-97453.0
Configuration: Network
A typical, complete CSI 2600 system is shown in the table, CSI 2600
system. IP addresses are unique addresses which systems on a
network use to communicate with each other. Three are shown:
Laptop (192.168.0.1)
Note
The IP addresses shown in this manual are examples only. Each system will have
a unique IP address.
26
IP address of the laptop must match a value stored in nonvolatile memory in each CSI 2600 processing board.
Reference Manual
MHM-97453.0
March 2011
192.168.0.1
192.168.0.10
192.168.0.11
BFP61.rbm (example)
C:\inetpub\ftproot\bin\
Services (4):
CSI_MhmRemote, CsiMtdbMgr,
CsiNetAdmin, CsiO_Server
192.168.0.10
192.168.0.11
Laptop IP:
192.168.0.1
Configuration: Memory
The CSI 2600 is a continuous online monitoring system. Once
configured, and until stopped, it will collect both predictive and
transient measurements, storing them in an AMS Machinery
Manager database and archives, respectively.
For the transient channels, the CSI 2600 continuously writes
waveform measurements to the Hard Disk Drive (HDD). When the
drive fills up, the system will begin writing over the oldest
measurements.
27
Reference Manual
MHM-97453.0
28
Reference Manual
MHM-97453.0
March 2011
CSI 2600
The CSI 2600 monitoring unit consists of:
An Ethernet connection
Power input
The AC power connection has an IEC 320 C13 receptacle. A North
American 3-prong plug (NEMA 5-15P) is provided. However, the
unit may be powered with either 110 V / 60 Hz or 220 V / 50 Hz
input power. No internal switches need to be adjusted to select
power type.
Note
The quality of the power provided to the CSI 2600 is very important. Although
the CSI 2600 contains input protection and some degree of line conditioning, it
is important to provide the unit with good clean power when the power is
ground isolated from the production equipment.
29
Reference Manual
MHM-97453.0
Ethernet ports
The NIC port may be used when connecting the CSI 2600 to a LAN.
The HUB port may be used when connecting directly to the laptop
in situations where connection to the plant LAN is either not desired
or not available.
Signal inputs
The CSI 2600 is designed to receive voltage signals from sensors or
external modules. The online database will include voltage-tovibration conversion specifics, such as sensitivity, DC and AC alarm
levels, offsets (if any). But the system expects voltage signals.
Signals such as 4-20 mA, RTDs, Thermocouples require external
conditioning electronics (normally a programming or terminal
option with installed modules to which the CSI 2600 connects).
The 4 tachometer inputs on the CSI 2600 rear panel also provides
BNC connections for up to 4 tachometer signals. These tachometers
can be used for both prediction and transient signal collection.
Note
Not all signals connected to a CSI 2600 need to be designated as transient.
Some signals do not carry unique transient information, and an analyst does not
wish to include high-speed samples of these signals in transient archives. These
are referred to in this manual as prediction signals. Others, such as radially
mounted pairs of proximity probes, do carry significant transient information.
These are referred to in this manual as transient signals.
30
Reference Manual
MHM-97453.0
31
Reference Manual
MHM-97453.0
A CSI 2600 alarm relay state may be based upon either overall
vibration value (i.e., the attached module), or Analysis
parameter signal level (i.e., energy at 1x turning speed, energy
at 2x turning speed)
32
Reference Manual
MHM-97453.0
March 2011
Hardware configuration
Introduction
Description
The 6560 Processor Module (in combination with the 6510 Signal
Input Module) is a multi-channel, multi-tasking, multi-processor
data acquisition system primarily intended for monitoring heavy
industrial rotating machinery. Typical signal inputs are dynamic AC
machine vibration signatures from accelerometers, velocity probes,
or proximity probes. These signals include two components: the
dynamic AC component, which represents machine vibration, and a
DC component, which represents the sensor bias level. In the case of
a proximity probe, the DC component represents the gap, or
average distance between the probe tip and the machine shaft.
Other signal inputs include process signals; these are DC parameters
such as temperature or pressure.
Tachometer inputs are used to determine machine speed. These
tachometer signals are typically generated from a proximity probe
or passive magnetic sensor positioned at a machine shaft keyway or
gear, producing a pulse train (not necessarily 1x machine speed)
representing the machine phase and running speed.
A final class of inputs are digital inputs which represent machine
states, such as running, off, starting, etc. These inputs are used to
control or modify the data acquisition state. Common state control
inputs are relay closures or machine RPM. AC or DC signal levels can
also be used for state control.
33
Reference Manual
March 2011
MHM-97453.0
To install a module, line up the guide rails and push the module into
the slot until fully seated, then tighten the mounting screws.
To remove a 6U high module, loosen the mounting screws, push
outward on the handles as shown to eject the module from the
backplane connectors, then pull from the slot by the handle.
Monitoring Methods
The 6560 uses three basic data monitoring methods.
Reference Manual
MHM-97453.0
March 2011
Spectral Scan
Spectral Scan is defined as the acquisition and analysis of dynamic
AC signals only. The signals are acquired, two channels at a time
(referred to as CHX and CHY), with a dual channel delta-sigma ADC
controlled by the system DSP. The DSP performs analysis of the
acquired time waveforms and transmits the results to the CPU host
processor. Pre-programmed groups of Spectral Scan measurement
parameters (AP Sets) may be assigned to specific machine state
conditions to tailor data acquisition to specific machine operational
states.
Configuration
The CSI 2600MS has a 6560 Processor module, and one or two 6510
Signal Input modules.
The CSI 2600TS has a 6560 Processor module with a Transient
Daughterboard, and one or two 6510 Signal Input modules with
Transient Filter Boards.
35
Reference Manual
MHM-97453.0
Processor Module
The 6560 provides all data acquisition, data storage, and data
communications functions for the CSI 2600 system. The 6560 is
capable of simultaneous, continuous measurement of detailed
Spectral analysis on two channels, RMS and DC values for Gross Scan
measurements on all signal channels, machine speed measurement
on all tachometer channels, and the states of all digital inputs.
The 6560 provides all data acquisition, data storage, and data
communications functions for the CSI 2600 system. The 6560 is
capable of up to 24 simultaneous and continuous waveform
measurements (for detailed Spectral analysis), up to 24 RMS and DC
values for Gross Scan measurements, up to 4 tachometers for
machine speed measurement, and up to 4 digital state inputs.
Gross Scan values, tachometer values, and digital input states may
be combined logically to determine machine operating state, which
may be used to define specific data acquisition states. The system
can be configured to transmit and store data on either time interval
or based on the amount of change of the data values.
Two 100Base-T Ethernet ports and one RS-232 serial port are
provided for system communications and diagnostics. Additional
connections are available for the calibration signal and a dry contact
SPDT "Sysfail" relay. (See diagram of backplane.) This relay is
energized when the Processor CPU successfully boots. On a CPU
failure or power loss, the relay will de-energize.
36
Reference Manual
MHM-97453.0
March 2011
32 MB SDRAM, 32 MB Flash
Network Communication
Local Communication
SPDT 24
DC Scan
16 bit
Data Collection
Event-based adaptive
Dynamic Range
Spectral Resolution
Analysis Bandwidth
37
Reference Manual
March 2011
MHM-97453.0
5% 0.2 Hz - 0.5 Hz
2% 0.5 Hz - 25 kHz
4% 25 kHz - 40 kHz
Frequency Accuracy
3% 0.5 Hz - 3 Hz
2% 3 Hz - 1 kHz
5% 1 kHz - 5 kHz
Averaging Types
Units Types
Scaling Types
Linear, Log, dB
Windows Types
Hanning, Uniform
38
Reference Manual
MHM-97453.0
March 2011
39
MHM-97453.0
40
Reference Manual
Reference Manual
MHM-97453.0
March 2011
Gain
/2
x1
/1
x1
/2
x10
/1
x10
Reference Manual
MHM-97453.0
Tachometer Inputs
The Tachometer inputs allow measurement of two pulse
tachometer sources per 6510 Signal Input module. Tachometer
sensor types may include, but are not limited to: active
displacement sensor, passive magnetic, or TTL pulse type from
various sources.
The Tachometer Input module features either fixed voltage trigger
or adaptive automatic triggering. Triggering parameters may be
set independently for each tachometer sensor input.
An input gain selection of x1 or x5 may be selected for each channel.
A gain of x5 is recommended for tachometer inputs smaller than 1 V
pk-pk. If the x5 input gain is used, care should be taken to make sure
that the input signal remains within +/-24 V, including any sensor
bias or gap voltage.
Note
AC relays are not provided.
42
Reference Manual
MHM-97453.0
March 2011
43
Reference Manual
March 2011
MHM-97453.0
Analysis Bandwidth
0.5 Hz
DC Accuracy
Analog Integration
AC Input Range
DC Input Range
+22 VDC
+22 V
Sensor Power
1 MOhm (differential)
44
Reference Manual
MHM-97453.0
March 2011
Displacement, AC or DC process
RMS to DC Converter
0.1%
Tachometer Resolution
Tachometer Types
Pulse Characteristics
Modes
Input Impedance
1 MOhm (differential)
Relay Type
10 mA @ 24 VDC
5 VDC - 24 VDC
<3 VDC
Each I/O Relay channel on the 6510 Signal Input module contains
both input and output hardware. The relays are configurable as
either input or output relays, with a DIP switch (SWI) on the circuit
board. A relay channel that is configured in software cannot be
utilized unless the corresponding DIP switch is set to the correct
position. The firmware will detect the DIP switch state at startup
and generates a flag in the HyperTerminal session if the software
45
Reference Manual
MHM-97453.0
configuration does not match the DIP switch setting. The DIP
switches are used to protect a user input device from inadvertently
being shorted by a relay output configuration. Set the
corresponding DIP switch to the ON position for output relays,
and to the OFF position for input relays. The factory default state
of the DIP switches is OFF (Input). DIP switch 1 is for the first relay
channel and DIP switch 2 is for the second relay channel.
The shelf state of the output relays is normally open, meaning that
when they are open the power is disconnected. During operation of
the unit, the relays are closed until activated by an alarm, then they
open.
Transient Daughterboard
The Transient Daughterboard adds the capability for parallel,
continuous time waveform acquisition on all channels. All collected
time waveform data, along with Overall Level data and up to four
tachometer pulse records is stored on an internal hard drive, which
provides approximately 80 minutes per GB of storage.
The Transient Daughterboard can also stream data via Ethernet to
analysis applications in near real time, without affecting data
collection or on-board data storage.
While collecting time waveforms and tachometer pulses, the
Transient Daughterboard continuously calculates the peak-to-peak
value of each channel's waveform. When configured, this value may
be sent to the 6560 Processor module for use as the overall level
instead of the RMS value produced by the 6510 Signal Input
module.
The hard drive used on the Transient Daughterboard is specially
rated for 24/7 operation. It is recommended that this drive be
replaced on a yearly basis of continuous use. In emergencies, any 21/2 inch parallel IDE drive may be used temporarily, but these drives
are not generally rated for continuous operation.
When installing the Transient Daughterboard on the 6560 Processor
module, make sure all five mating connectors are fully engaged, and
then install all six mounting screws.
46
Reference Manual
MHM-97453.0
March 2011
Up to 24 channels
Memory Capacity
64 MB SDRAM, 16 MB Flash
5% 0.2 Hz - 0.5 Hz
2% 0.5 Hz - 2 kHz
Frequency Accuracy
3% 0.5 Hz - 3 Hz
2% 3 Hz - 1 kHz
5% 1 kHz - 5 kHz
1X Phase Accuracy
THD
ADC Resolution
16 bits
Spectral Resolution
Dynamic Range
>80 dB
80 GB, upgradeable
Communications
47
Reference Manual
MHM-97453.0
48
Reference Manual
MHM-97453.0
March 2011
2.
Gently remove the hard drive ribbon cable from the hard drive
and remove the old hard drive.
3.
Install the new hard drive in the bracket. Do not over tighten
the screws.
49
Reference Manual
MHM-97453.0
4.
Launch DHM_III.exe
2.
3.
When the drive has been formatted, reboot the CSI 2600. Again,
ignore any hard drive error messages produced by the Transient
Daughterboard on the HyperTerminal monitor. When the POST
process is complete, the firmware will automatically prepare the
hard drive with the Transient File System. This process may take up
to an hour. When this process is complete, reboot the CSI 2600. The
boot process should now complete normally, with no hard drive
error messages, and, if configured, Transient data collection should
begin (indicated by a flashing hard drive indicator on the Processor
front panel).
Note
Emerson provides an industrial rated HDD, capable of 100% duty cycle. Emerson
recommends that an equivalent replacement HDD be utilized.
50
Reference Manual
MHM-97453.0
March 2011
Transient Filter Boards may be used to configure either a 12- or 24channel Transient System.
When installing the Transient Filter Board on the Signal Input
module, make sure both mating connectors are fully engaged, then
install all three mounting screws.
Number of channels: 12
Attenuation: 80 dB
51
Reference Manual
MHM-97453.0
52
Reference Manual
MHM-97453.0
March 2011
9600 baud
8 data bits
1 stop bit
no parity
no flow control
Turn power on to the CSI 2600. From here, you can watch the boot
process. You may interrupt boot by pressing the Space bar after
the VxWorks copyright is displayed as shown below. By the time
Press any key to stop auto-boot is displayed, most of the time
allotted for pressing a key has passed. Interrupting the boot process
will allow the configuration of boot specific parameters.
VxWorks System Boot
Copyright 1984-2002 Wind River Systems, Inc.
CPU: CSI 6500
Version: 5.5
BSP version: 1.2/4.00f
Creation date: May 5, 2008, 10:38:03
Image: bootrom
Press any key to stop auto-boot...
Last Calibrated
53
Reference Manual
March 2011
MHM-97453.0
---------------- ------------------------------------DIO
2008-08-13 19:09:25
GS
2008-08-13 19:09:25
TACH
2008-08-13 19:09:25
SCHED
2008-08-13 19:09:26
PRED
2008-08-13 19:09:25
LIMIT
2008-08-13 19:09:26
TRANS
2008-08-13 19:09:29
EGU_FAC
Default Table
EGU_ASN
Default Table
/browser/ - Volume is OK
Base Modbus register table size (excluding DCS info): 0xcf8a
(53130)
This unit will begin announcing its availability in 84 seconds
Navigation
The following list is printed to the screen by interrupting boot and
typing ? or help.
54
Reference Manual
MHM-97453.0
March 2011
g adrs - go to adrs
Note
When modifying an entry simply type new setting in, do not attempt to
backspace over existing entry.
55
Reference Manual
March 2011
MHM-97453.0
Changing configuration
Once the boot process has been interrupted, you should get the
prompt [VxWorks Boot]: At this prompt, type c and press Enter
to configure the unit. Each parameter in the configuration will be
brought up and you can type a new value and press Enter to
replace the old value, press Enter to accept the old value, type .
and press Enter to clear the value or type - and press Enter to
go back to the previous parameter.
: shend0
processor number
:0
host name
file name
:bin/6500
:192.168.0.10:ffffff00
:192.168.0.1
user (u)
:anonymous
56
flags (f)
:0x1009
other (o)
Reference Manual
MHM-97453.0
March 2011
: shend0
processor number
:0
host name
file name
: bin/6500t
:192.168.0.11ffffff00
:192.168.0.1
user (u)
:anonymous
:anonymous
flags (f)
:0x1409
other (o)
57
Reference Manual
March 2011
MHM-97453.0
The 0x0800 flag applies only if one of the three flags below is set:
0x1000 - attempt network, fallback on FLASH boot (legacy 4500
mode)
0x2000 - boot ALWAYS from network, never fallback on FLASH
0x4000 - boot ONCE from network. This flag clears itself after one
boot
The system will normally try to get boot parameters, boot image,
and startup script first from FLASH. If the FLASH boot fails, the
system will revert to a network boot as a backup. The 0x1000,
0x2000, and 0x8000 flags modify this default behavior (listed with
highest precedence first).
58
CPU
With Bootp
Without Bootp
Main
0x1449
0x1409
Transient
0x1449
0x1409
Reference Manual
MHM-97453.0
March 2011
Subnet masks
A subnet mask is normally represented in Windows as a series of four
decimal numbers, each of which can have a value from 0 to 255,
separated by periods (e.g., 255.255.248.0).
In the 6560 Processor module, the subnet mask is represented as a
series of four hexadecimal pairs with no separators (that is,
255.255.248.0 is represented as fffff800). A hexadecimal
conversion table can be used to convert the subnet mask numbers
from decimal to hexadecimal. The calculator in the Windows'
Accessories folder will also perform this conversion when it is set to
the scientific mode.
The subnet mask on a 6560 Processor module defaults to
255.255.255.0 (ffffff00). When configuring the 6560 Processor
module, the subnet mask should be set to match the subnet mask
used on the server PC. If they do not match, network
communication failure is possible. To specify a subnet mask, enter it
on the configuration labeled "inet on ethernet." The IP address of the
unit should be entered first, followed by a colon and then the subnet
mask in the hexadecimal format.
59
Reference Manual
MHM-97453.0
Input Power
The Input Power LED indicates the status of the power converters
that distribute various voltages within the 6560 Processor module.
A steady green color indicates that all power converters are within
the proper voltage ranges, while a steady or blinking red condition
indicates a power fault somewhere inside the 6560 Processor
module.
60
Reference Manual
MHM-97453.0
March 2011
CPU Status
The CPU Status LED indicates the status of the Main Processor
board. The four (4) status conditions are listed in Table 6 along with
their assigned priorities.
Note
It is possible for more than one status condition to be active at one time. When
this happens, the LED will indicate the active status condition with the highest
priority. For example, if the module is both Uncalibrated (3) and is also
currently Performing POST (1), the LED would indicate Performing POST.
Additionally, if the module is both Uncalibrated (3) and in Failure (2) then
the LED will indicate the Failure.
Status
Priority
Comments
Blinking Green
In POST
Solid Red
Failure
Alternating Red/Green
Uncalibrated
Solid Green
OK
Normal Operation.
Transient Status
The Transient Status LED indicates the status of the Transient
Daughter Board. The LED is always off when a Transient board is not
installed in the system. The four (4) Transient board status
61
Reference Manual
March 2011
MHM-97453.0
Status
Priority
Comments
Blinking Green
In POST
Solid Red
Failure
Alternating Red/Green
Uncalibrated
Solid Green
OK
Normal Operation.
System Status
The System Status LED indicates the status of the overall system. It
reflects the worst case state of all boards in the system. For
example, if the Test Function generator on the Main Processor board
is uncalibrated, and the first MSIG module has a power fault, then
the LED will show a solid red color to indicate the worst case of these
two which is a Failure state.
When all the firmware components are operating as expected, this
LED overlays a heartbeat pulse pattern on top of the system
status. The heartbeat pattern occurs in a 4-count cycle. The LED is
pulsed off briefly during each of the first and second counts, and
then left on during the 3rd and 4th counts. In practice, it gives the
appearance of a human heartbeat. If the heartbeat stops, it
indicates a firmware fault has occurred. Many times the system is
capable of recovering from a missed heartbeat. However, if the
62
Reference Manual
MHM-97453.0
March 2011
Server Connect
The Server Connect LED indicates when Machinery Health Manager
software or the DHM diagnostic software are connected. A green
color indicates that at least one Machinery Health Manager software
client is connected or that the DHM software is connected in the
client mode. A red color indicates the DHM software is connected in
the Single User mode. In this state, no other clients can connect. If
the LED is OFF it indicates that none of these types of software
clients are connected. There is no indication of client data transfer,
only the presence of at least one established connection.
Modbus Connect
The Modbus Connect LED indicates when a Modbus client, Web
Browser, or Transient Live client are connected. A green color
indicates that at least one of these types of clients has established a
connection. If the LED is OFF it indicates that none of these types of
clients are connected. There is no indication of client data transfer,
only the presence of at least one established connection. The red
color is not used with this LED.
63
Reference Manual
MHM-97453.0
Power LED
The Power LED indicates the status of the MSIG module power
converters. A steady green color indicates that all voltage levels are
OK, while a steady or blinking red condition indicates a power fault
somewhere within the module.
64
Reference Manual
MHM-97453.0
March 2011
Status LED
The Status LED indicates the overall status of the module. The four
(4) module status conditions are listed in Table 8 along with their
assigned priorities.
Note
It is possible for more than one status condition to be active at one time. When
this happens, the LED will indicate the active status condition with the highest
priority.
If the Status LED is off entirely, it indicates that this module is being
ignored by the 6560 Processor module. This is a special case which
should not be encountered in practice. Modules are only ignored if
the addition of the module would exceed the maximum channel
count limits that the 6560 Processor module can support (24
analog, 4 Tach, 4 I/O) as channels are counted starting in the left
most slot and working toward the right.
Table 8: Signal Input Module LED Status
LED Color
Status
Priority
Comments
Blinking Green
In POST
Solid Red
Failure
Alternating Red/Green
Uncalibrated
Solid Green
OK
Normal Operation.
65
Reference Manual
MHM-97453.0
Data types
Overall Level Parameters
All Overall Level inputs must be DC in nature. Any Overall Level input
of a dynamic nature must be fed through the RMS / DC converter
path. It is not technically valid to convert RMS values from an
RMS/DC converter to pk or pk-pk Measurement Units unless the
input is sinusoidal in nature. However, the CSI 2600 allows this. RMS
values are multiplied by 1.414 or 2.828 to convert from RMS to pk
and pk-pk, respectively.
Spectral Scan Parameters
All Spectral Scan Parameters must be AC in nature. It is possible to
convert some analysis type results between Measurement Unit
types and Display Unit types.
Analysis Type: Overall Level
Includes Overall RMS Level, Sensor DC Bias, Gap, DC, or AC Process
signals.
Note
Some DC Process Inputs could provide pk, pk-pk, or other Measurement Units.
66
Reference Manual
MHM-97453.0
March 2011
Input Unit
HW Int.
RMS/DC
Meas.
Unit
Disp.
Unit
DC
V / E.U.
no
no
DC
E.U.
AC
V / E.U.
no
yes
RMS
E.U.
ACCEL
V / 32.2 ft/s
no
yes
RMS
V / 32.2 ft/s
yes
yes
RMS
in./s
V / 9.81 m/s
no
yes
RMS
V / 9.81 m/s
yes
yes
RMS
mm/s
V / i/s
no
yes
RMS
i/s
V / i/s
yes
yes
RMS
mil
V / mm/s
no
yes
RMS
mm/s
V / mm/s
yes
yes
RMS
micron
V / mil
no
yes
RMS
mil
V / micron
no
yes
RMS
micron
VEL
DISP
Note
RMS, pk, pk-pk Measurement Units are valid and can be freely converted.
67
Reference Manual
March 2011
MHM-97453.0
Input Unit
HW Int.
SW Int.
SW
Diff.
Disp.
Unit
AC
V / E.U.
no
no
no
E.U.
ACCEL
V / 32.2 ft/s
no
no
no
V / 32.2 ft/s
no
single
no
in./s
V / 32.2 ft/s
no
double
no
mil
V / 32.2 ft/s
yes
no
no
i/s
V / 32.2 ft/s
yes
single
no
mil
V / 32.2 ft/s
yes
no
single
V / 9.81 m/s
no
no
no
V / 9.81 m/s
no
single
no
mm/s
V / 9.81 m/s
no
double
no
micron
V / 9.81 m/s
yes
no
no
mm/s
V / 9.81 m/s
yes
single
no
micron
V / 9.81 m/s
yes
no
single
68
Reference Manual
MHM-97453.0
March 2011
Input Unit
VEL
DISP
HW Int.
SW Int.
SW
Diff.
Disp.
Unit
V / i/s
no
yes
no
i/s
V / i/s
no
yes
no
mil
V / i/s
yes
no
mil
V / i/s
no
yes
single
V / i/s
yes
yes
single
i/s
V / mm/s
no
no
no
mm/s
V / mm/s
no
single
no
micron
V / mm/s
yes
no
no
micron
V / mm/s
no
no
single
V / mm/s
yes
no
single
mm/s
V / mil
no
no
no
mil
V / mil
no
no
single
i/s
V / mil
no
no
double
V / micron
no
no
no
micron
V / micron
no
no
single
mm/s
V / micron
no
no
double
Note
Measurement Unit Type is specific to Analysis Type. No Software Integration
Differentiation can be performed.
69
Reference Manual
March 2011
MHM-97453.0
Input Unit
HW Int.
Disp. Unit
AC
V / E.U.
no
E.U.
ACCEL
V / 32.2 ft/s
no
V / 32.2 ft/s
yes
in./s
V / 9.81 m/s
no
V / 9.81 m/s
yes
mm/s
V / i/s
no
i/s
V / i/s
yes
mil
V / mm/s
no
mm/s
V / mm/s
yes
micron
V / mil
no
mil
V / micron
no
micron
VEL
DISP
Offset adjustment
For thrust probes, the input channel is defined as a DC Process input.
To set the DC offset so that the thrust reading may be zeroed, use a
DC voltmeter (or the DHM program) to measure the DC voltage as
70
Reference Manual
MHM-97453.0
March 2011
seen directly on the inputs. Enter this value into the offset field in
the sensor set up page in OCONFIG.
2.
Transient
71
Reference Manual
March 2011
MHM-97453.0
Input
Output
(external) signal
GS (Gross Scan)
TSG signal
GS table
TSG signal
DSP table
Transient
TSG signal
Transient table
The TSG circuit provides an output signal, which is used to create all
of the other calibration tables. The TSG circuit has its own
calibration table, stored in the CPU board. If a CPU board is replaced,
then the other calibrations need to be rerun for that 6560 Processor
Module, since their (original) calibration tables used the TSG signal
from the original CPU board.
Calibration tables may be copied from each 6560 Processor Module
onto an online server, and those can be downloaded into the same
6560 Processor Module. Emerson Online Product Support
personnel, and Online Systems Engineers, can assist customers with
this type of operation.
Should it be desirable or necessary to recalibrate an installed
system, it is recommended that this be accomplished with the
support of the local Emerson Online Product Support office, and
that it be scheduled during an equipment outage. Calibrations can
be accomplished in less than an hour (per CSI 2600), but during that
time, the units cannot be monitoring rotating equipment.
72
Reference Manual
MHM-97453.0
March 2011
Cable which connects the Digital Multi Meter to the test port
on the CSI 2600
73
Reference Manual
March 2011
MHM-97453.0
annually.
DSP calibration
Digital Signal Processing (DSP) calibration:
annually.
Transient calibration
The CSI 2600T includes two processing boards; a Main Processor
board and a Transient board. Both boards include separate Digital
Signal Processors. The DSP on the Transient board uses an internal
74
Reference Manual
MHM-97453.0
March 2011
calibration table, in much the same way that the Main Processor DSP
circuit does. However, it is calibrated separately, it is not calibrated
as part of a DSP calibration for a Main Processor.
Transient calibration:
should be performed:
- annually
- whenever a 6510 Signal Input module is replaced
- whenever a Transient board is replaced
- whenever a Main Processor board is replaced
- if calibration table has a status of Unknown.
Online server
A laptop is a computer which has been configured to include:
75
Reference Manual
MHM-97453.0
Reference Manual
MHM-97453.0
March 2011
2.
3.
4.
Select Properties
5.
Scroll down in the text window at the center of the Local Area
Connection Properties pop-up screen, and select Internet
Protocol (TCP/IP)
6.
7.
Change IP address
77
Reference Manual
MHM-97453.0
78
Reference Manual
MHM-97453.0
March 2011
79
Reference Manual
MHM-97453.0
80
Reference Manual
MHM-97453.0
March 2011
Reference Manual
March 2011
MHM-97453.0
82
Reference Manual
MHM-97453.0
March 2011
2.
3.
Use the Enter key to advance down the list of parameters until
inet on ethernet comes into view. This is where the IP
address for the CSI 2600 is shown.
4.
2.
3.
4.
Select Properties.
5.
Reference Manual
MHM-97453.0
1.
2.
3.
4.
84
Reference Manual
MHM-97453.0
March 2011
These are the units which are available for the online server.
The IP address of the CSI 2600 CPU board should be listed in
this panel.
Click the Stop Data Collection button. The button label will
change to Start Data Collection, and while the system is
stopped, online server setup can be changed. Click the Edit
button beside the Active Units panel.
6.
7.
8.
85
Reference Manual
MHM-97453.0
9.
86
Reference Manual
MHM-97453.0
March 2011
2.
9600 baud
8 data bits
1 stop bit
No parity
No flow control
3.
4.
87
Reference Manual
March 2011
MHM-97453.0
CAUTION!
Do not attempt to backspace\delete the stored parameters.
Ctrl-B - (Hold down the Ctrl key and press the B key). This will
toggle from one board to the other (if serial port is connected
to CPU board, it will toggle to the Transient board).
reboot - (case sensitive, all lower case). This will cause the
board to reboot, using new boot settings.
Reference Manual
MHM-97453.0
March 2011
2.
3.
4.
5.
6.
7.
89
Reference Manual
MHM-97453.0
8.
9.
Press the Enter key until at the end of the parameter list.
10.
11.
Type Ctrl-B (hold Ctrl key down, press the B key) to switch
to the other (first) circuit board.
12.
Reference Manual
MHM-97453.0
March 2011
The user name and password are csi and csiSupport. Both are case
sensitive. A Telnet sequence is as follows:
1.
2.
Select Run from the server Start Menu, and type the
command telnet followed by the IP address of the circuit
board.
Figure 34. Telnet to CSI 2600 CPU board that has address 192.168.0.10
3.
4.
5.
91
Reference Manual
March 2011
MHM-97453.0
6.
7.
Type exit or close the Telnet window when you are done.
New boot settings will not take effect yet, not until the CSI
2600 is rebooted.
8.
Select Run from the server Start Menu, and open a Telnet
session with the other circuit board. Make changes as
necessary, review changes, close the Telnet window.
9.
Reboot the CSI 2600. Either toggle the power on and off, or
Telnet to the CPU board and type the command reboot.
Note
While the CSI 2600 is rebooting, it will not initially respond to a Telnet
command. Internal memory and processors must be initialized (late in the boot
sequence) before the system will respond to Ethernet commands (that is,
Telnet, reboot, bootChange).
92
Reference Manual
MHM-97453.0
March 2011
Parameters for a CSI 2600 system are shown in the figure, CSI 2600
CPU board boot parameters, and explained as follows.
WARNING!
Only the IP addresses should be change. If the other values are changed,
the unit will not successfully boot.
The host name is normally the name assigned to the online server
in RBM Network Administration.
Item 2 is the boot file name. The CPU and transient boards use
different boot files. These files are stored on the online server at
directory C:\Inetpub\ftproot\bin. When the CSI 2600 boots up, it
will search for the server, and in directory C:\Inetpub\ftproot, it
will look for subdirectory bin, and then the boot files within that
subdirectory.
Item 3 is the IP address of this circuit board (CPU board in this
example). This address must be listed in Machinery Health Manager
RBM Network Administration, Online Server Setup, to make the
unit available for databases.
Item 4 is the IP address of the server. This address is stored in
memory in both the CPU board, and in the Transient board. If the
93
Reference Manual
March 2011
MHM-97453.0
This series of tasks is different for a CSI 2600 application, than for
other online monitoring applications. In most cases, the CSI 2600 is
not connected directly to sensors (proximity probe drivers,
accelerometers, etc.). Rather, it is connected via coax cable with
94
Reference Manual
MHM-97453.0
March 2011
Reference Manual
MHM-97453.0
96
2.
3.
Click the down arrow button beside the Tach field, and
select the tachometer to be used during transient acquisition.
This will be a tachometer connected to CSI 2600 tach location
1, 2, 3, or 4.
Reference Manual
MHM-97453.0
March 2011
4.
5.
6.
Click OK.
97
Reference Manual
MHM-97453.0
When using the CSI 2600 to monitor turbo machinery, rely on the
following plots and measurements:
98
Resting DC voltage
Reference Manual
MHM-97453.0
March 2011
Bearing clearance
99
Reference Manual
MHM-97453.0
100
Reference Manual
MHM-97453.0
101
Reference Manual
March 2011
MHM-97453.0
102
Reference Manual
MHM-97453.0
March 2011
2.
3.
Reference Manual
MHM-97453.0
Note
In Figure 48,Commission Transient channels (1), channels 1-6 are already
commissioned for normal operation, as indicated by the green circle and
check mark at each channel connection.
Reference Manual
MHM-97453.0
March 2011
105
Reference Manual
March 2011
MHM-97453.0
106
Reference Manual
MHM-97453.0
March 2011
107
Reference Manual
MHM-97453.0
108
Reference Manual
MHM-97453.0
March 2011
109
Reference Manual
MHM-97453.0
Reference Manual
MHM-97453.0
March 2011
Tachometer definitions
Relay definitions
111
Reference Manual
March 2011
MHM-97453.0
112
Reference Manual
MHM-97453.0
March 2011
Reference Manual
MHM-97453.0
Note
The transient drive is the location where transient data is recorded during
normal/constant CSI 2600 operation. Measurements from this drive are
extracted when an archive is created, and sent as a folder (archive to the online
server.
The Transient Status tab also shows the time of oldest and newest
measurements currently stored in the CSI 2600 for a specific
database configuration. These fields may be updated by clicking the
Refresh button.
The final status indicator is the state of transient auto-archive
predicate. For the Online Watch: Transient Status tab, the database
is using a collection predicate which is TRUE if speed is above 1500
RPM and below 2985 RPM. Actual speed for tachometer signal 13 is
shown, it is 187 RPM. Therefore the collection predicate is FALSE, as
shown in the last column.
When the auto-archive predicate changes to TRUE, an analyst may
select the second tab Transient Archive Status to monitor progress
of archive creation.
For the Auto-Archive Predicate = TRUE (Figure 60) and Auto-Archive
status = Archiving (Figure 61) screens, the auto-archive definition
created in Online Configuration is to create archives with a name of
RANGE 1500_2985 (plus date-time stamp), and to include 5
minutes of measurements before the predicate changes to TRUE,
and then 2 minutes of measurements that follow. For the sequence
shown in the Figure 60, Auto-Archive Predicate=TRUE and Figure
114
Reference Manual
MHM-97453.0
March 2011
115
Reference Manual
MHM-97453.0
Inside folder CSI 2600 there are a collection of other folders. One
of these, the archives folder, is where archives of transient
information are stored.
Three specific transient operations may also be performed using
Online Watch. These are:
116
Reference Manual
MHM-97453.0
March 2011
2.
3.
117
Reference Manual
MHM-97453.0
2.
3.
Reference Manual
MHM-97453.0
March 2011
1.
2.
3.
4.
5.
6.
No archive is created.
7.
8.
9.
10.
11.
119
Reference Manual
MHM-97453.0
Analysts may remove items from the Transient Archive Status tab
(Figure 69, Acknowledging Transient Archives). This does not delete
archives from the online server, it only removes them from the list
shown on the Transient Archive Status tab. To remove an archive
from the listing, right click on it and select Acknowledge Transient
Archive.
Managing archives
Typical CSI 2600 operation will involve moving around, and
examining, extremely large amounts of transient information. A one
hour archive for a CSI 2600 which has 10 channels commissioned for
transient operation, will be approximately 400 MB in size. The CSI
2600 will permit an analyst to manually extract 10, 20, 30, etc.
hours of measurements from the CSI 2600. Obviously, these files
can be extremely large. Even an online server with a very large HDD
will eventually fill up.
Efficient CSI 2600 system operation will be achieved if the analyst
regularly reviews extracted archives (automatic, manual), and keeps
120
Reference Manual
MHM-97453.0
March 2011
WARNING!
Ensure that the following sequence is observed, whenever moving the
CSI 2600 from one monitoring rack/machine to another. Incorrect performance of this sequence could result in the storage of one (the second
machine) in the database of another (the first machine).
1.
Note
You will need to logon to AMS Machinery Health Manager as an Administrator to
access this program.
121
Reference Manual
March 2011
MHM-97453.0
3
2.
122
Reference Manual
MHM-97453.0
March 2011
3.
4.
Disconnect the CSI 2600 from the first machine, move to the
second machine.
5.
6.
123
124
Reference Manual
MHM-97453.0
Reference Manual
MHM-97453.0
March 2011
Also during the lifetime of a CSI 2600 system, an analyst may need
to troubleshoot one of the following situations:
125
Reference Manual
MHM-97453.0
Each time the CSI 2600 starts up, it steps through the following
sequence:
126
1.
2.
3.
Enter Online Config and click on the level below the unit
branch of the tree to bring up the CSI 2600 mimic screen.
4.
Right click on the CSI 2600 and select Properties. Verify that
the firmware revision listed matches what was just installed.
Reference Manual
MHM-97453.0
March 2011
2.
3.
Right click the online server from the bottom center panel and
select Online Server Setup.
4.
Click the Stop Data Collection button. This is a multipurpose selector and not a status indicator. it is used to both
stop and start data collection. The button is labeled with the
127
Reference Manual
MHM-97453.0
5.
Software patches
If software patches (changes to one or more of the Machinery
Health Manager software programs, but not to all of them) are
supplied, the following sequence should be used.
1.
128
Reference Manual
MHM-97453.0
March 2011
2.
3.
4.
2.
3.
129
Reference Manual
MHM-97453.0
4.
130
Reference Manual
MHM-97453.0
March 2011
Note
Do not add a CSI 2600 to an existing Ethernet network until its IP addresses (CPU
board, Transient board) have been verified and changed if necessary, to be
compatible with addresses already in use on the existing network.
9600 baud
8 data bits
1 stop bit
No parity
No flow control
131
Reference Manual
MHM-97453.0
Connect the serial cable to both the CSI 2600 9-pin connection, and
the laptop. Open operating system utility HyperTerminal. This is
usually selected from Programs > Accessories > Communications>
HyperTerminal, as shown in Figure 78, HyperTerminal utility.
Ctrl-B - (Hold down Ctrl key and press the B key.) This will
toggle from one board to the other (if serial port is
communicating with the CPU board, Ctrl-B will toggle to the
Transient board).
reboot - (case sensitive, all lower case). This will cause the
board to reboot, using new boot settings.
Reference Manual
MHM-97453.0
March 2011
CAUTION!
Do not change ftp password, boot file name, flags, etc. If a unit boots up
with incorrect values for these parameters, the system will probably not
operate and in some cases, the unit may need to be returned to Emerson.
2.
3.
4.
5.
133
Reference Manual
March 2011
MHM-97453.0
6.
7.
At the end of the list, type Ctrl-B (hold Ctrl key down, press
the B key) to toggle to the other circuit board.
8.
9.
10.
Press the Enter key until at the end of the parameter list.
11.
134
Reference Manual
MHM-97453.0
March 2011
12.
13.
General
There are other maintenance activities which may need to be
performed during the product life of the CSI 2600. These can
include:
Recalibration
Board replacement
Troubleshooting: Measurements in
Online Watch and/or Diagnostic Analysis
appear incorrect
Since the CSI 2600 is a portable system using existing field wiring, it
is likely that CSI 2600 values will be compared to values measured
by some other instrument (that is, the monitor rack which the CSI
2600 connects to, or a hand-held vibration monitoring instrument
such as the CSI 2130).
If two instruments are showing different measurements for the
same signal, it is likely that:
Reference Manual
MHM-97453.0
Reference Manual
MHM-97453.0
March 2011
If Gross Scan DC values shown in Online Watch are not typical for
the type of sensor in use, the module which the CSI 2600 is
attached to is probably conditioning the output signal. In this case,
the CSI 2600 database must be updated (using program Online
Configuration).
The CSI 2600 product expects sensor signals whose voltage is
proportional to vibration or position. This is not the case with a 4-20
mA output from a monitoring module (current is proportional to
vibration or position). If 4-20 mA signals are provided to the CSI
2600, then a suitable sized resistor needs to be placed in parallel
137
Reference Manual
March 2011
MHM-97453.0
with sensor BNC inputs (across ground and signal), to convert the
current to voltage.
138
Reference Manual
MHM-97453.0
March 2011
2.
3.
4.
Reference Manual
March 2011
MHM-97453.0
2.
3.
4.
Select Properties.
5.
6.
140
1.
2.
3.
4.
5.
6.
7.
Reference Manual
MHM-97453.0
March 2011
8.
9.
141
Reference Manual
MHM-97453.0
Scroll down in the listing until the flags are shown. If there was
a POST failure, a flag will be set, and the title of the failure will
also be listed.
142
Reference Manual
MHM-97453.0
March 2011
Scroll down in the listing until the Transient board flags are
listed.
These steps will not correct a POST failure, but they will give more
details. It is possible that a failed unit may temporarily be used in a
specific application, prior to shipment back to CSI for repair. For
instance, if a signal path on the circuit board with signals 17-32 has
failed, but the analyst wishes to operate the system in a
configuration that only uses signal connections at 1-16, the system
may function for that measurement.
Reference Manual
March 2011
MHM-97453.0
Note
If CSI 2600 CPU address is different, type that address instead of 192.168.0.10.
144
Reference Manual
MHM-97453.0
March 2011
145
Reference Manual
March 2011
MHM-97453.0
146
Reference Manual
MHM-97453.0
March 2011
archive predicate, a pop-up window will ask him or her to verify this
request.
A transition from Disabled to TRUE will not cause an archive to
be created. Consider the following sequence for the predicate
shown in Figure 92, Disabling Archive Predicate (archive will be
created when speed goes above 1500 RPM, or drops below 2985
RPM from a higher speed):
147
Reference Manual
March 2011
MHM-97453.0
This condition is indicated on the Transient Status tab for the CSI
2600 unit.
148
Reference Manual
MHM-97453.0
March 2011
149
Reference Manual
MHM-97453.0
150
Reference Manual
MHM-97453.0
March 2011
151
Reference Manual
March 2011
MHM-97453.0
Backplane:
8. SysFail relay connector
9. DC Power input connector for Prediction Side
10. HUB network connector
11. NIC network connector
12. Chassis Ground lug
13. Power On LED
14. +24 V Input LED
15. Status LED
Note
For the TACH and Relay channels, the DIP switches must be left in the OFF
position.
152
Reference Manual
MHM-97453.0
March 2011
Note
For the CSI 2600, this connection is not used and the -24 V power is available on
the panel-mounted Phoenix connector on the rear of the case.
The last terminal for each channel is a chassis ground for connecting
the sensor cable shield.
153
Reference Manual
March 2011
MHM-97453.0
J2
J3
SIG+ 1 / +24V
SIG+ 5 / +24V
SIG+ 9 / +24V
Tach+ 1
Tach- 1
-24V
-24V
-24V
-24V
SIG+ 2 / +24V
SIG+ 6 / +24V
SIG+ 10 / +24V
Tach+ 2
Tach- 2
-24V
-24V
-24V
-24V
SIG+ 3 / +24V
SIG+ 7 / +24V
SIG+ 11 / +24V
I/O+ 1
I/O- 1
-24V
-24V
-24V
-24V
Shield
Shield
Shield
Shield
SIG+ 4 / +24V
SIG+ 8 / +24V
SIG+ 12 / +24V
I/O+ 2
I/O- 2
-24V
-24V
-24V
-24V
*NOTE: -24V terminals on I/O channels are not used for I/O connections.
154
J4
Reference Manual
MHM-97453.0
March 2011
J6
J7
J8
SIG+ 13 / +24V
SIG+ 17 / +24V
Tach+ 3
Tach- 3
-24V
-24V
-24V
-24V
Shield
Shield
Shield
Shield
SIG+ 14 / +24V
SIG+ 18 / +24V
SIG+ 22 / +24V
Tach+ 4
Tach- 4
-24V
-24V
-24V
-24V
Shield
Shield
Shield
Shield
SIG+ 15 / +24V
SIG+ 19 / +24V
SIG+ 23 / +24V
I/O+ 3
I/O- 3
-24V
-24V
-24V
-24V
Shield
Shield
Shield
Shield
SIG+ 16 / +24V
SIG+ 20 / +24V
SIG+ 24 / +24V
I/O+ 4
I/O- 4
-24V
-24V
-24V
-24V
Shield
Shield
Shield
Shield
*NOTE: -24 V terminals on I/O channels are not used for I/O connections.
155
Reference Manual
March 2011
MHM-97453.0
156
Reference Manual
MHM-97453.0
March 2011
158
Reference Manual
MHM-97453.0
Reference Manual
MHM-97453.0
Index
A
Accessories
optional 9
services 9
provided 7
recommended 3, 8
archive
truncated 148
B
Backplane 152
BNC connectors 151
boot parameters
changing
rules 132
boot parameters rules 88
boot setting
CSI 2600
hyperterm session 131
boot settings 130
C
Configuration 35
CSI 2600 20
Calibrating 71
Field Wiring 24
Installing 2600 modules 34
Introduction 17
monitoring unit 29
Operating environment 9
Overview 5
CSI 2600 Configuration
Memory 27
Network 26
CSI 2600 Machinery Health Expert 5
D
Database Structure 22
March 2011
Collection Criteria 23
Logical Hierarchy 24
Physical Hierarchy 24
Definitions, terms 81
Archive 81
Archive predicate 82
Bearing clearance 82
Extract 82
HDD (Hard Disk Drive) 82
Resting DC Voltage 82
Transient channel 82
Diagnostic Analysis 21
measurements
appear incorrect 135
Diagram
online database structure 23
system overview 18
Dimensions and weights 6
Disconnecting the laptop 13
F
Firmware
CSI 2600 22
H
HyperTerminal 13
HyperTerminal, Configuring a CSI 2600 52
I
internal wiring diagram 156
Internal Wiring of the CSI 2600 151
IP address
changing network addresses 85
IP addresses 26
change 133
verifying or editing 83
M
measurements
display
4 - 20mA conversion and compensation
159
Reference Manual
March 2011
138
changing display units 136
in what forms 136
Gross Scan DC readings 137
MHMRemote 21
Microsoft
IIS FTP 21
Monitoring Methods 34
MtDbMgr 20
N
NAS hard drive 15
NetAdmin 20
new firmware
installing 125
new software
installing 127
patches 128
services 129
Node(Unit)Down
CSI 2600
troubleshooting 138
MHM-97453.0
S
Signal Input Module 41
Spectral Scan 35
System Status LED is red 141
T
telnet 142
csiSupport 142
showUnitStatus 142
Transient Archive
cancel 150
status tab 150
Transient Data Capture 35
Troubleshooting
automatic archive not created 145
database
unable to change 149
online server and CSI 2600 do not
communicate 143
W
Windows Services 19
O
O_server 20
Online Configuration 21
Online Server 75
no communication with CSI 2600 143
ping 144
Online Software guide 32
Online Watch 21
measurements
appear incorrect 135
P
Power On Self Tests (POST) 141
power wiring detail 155
Processor Module 36
R
Rear Termination Panel 152
160